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Stihl TS 400 Cutquick, Руководство пользователя

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STIHL TS 400

5

DG screws are screwed into plastic and light metal parts. These screws cut a thread in the material when they are screwed

in for the first time. The material is permanently deformed. The screws can then be removed at will and retightened without

impairing the strength of the screw connection, provided that the specified tightening torque is maintained. It is therefore

essential to use a torque wrench.

2.6 Tightening torques

Size of
thread

IS-DG 4x14
IS-DG 4x15
IS-DG 4x15
IS-DG 5x20
IS-DG 5x20
M5
IS-M 5x16
IS-M 5x16
IS-M 5x16
IS-M 5x16
IS-M 5x16
IS-M 5x20
IS-M 5x20
IS-M 5x20
IS-M 5x20
IS-M 5x20
IS-M 5x20
IS-M 5x20
IS-M 5x20
IS-M 5x20
IS-M 5x25
IS-M 6x16
IS-M 6x16
IS-M 6x16
M 5x55
M 8x1
M 8x1
M 12x1 L
M 14x1.25
M 10x.. L

Connecting
element

Groove-headed screw
Socket-head screw
Socket-head screw
Socket-head screw
Socket-head screw
Nut
Socket-head screw
Socket-head screw
Socket-head screw
Socket-head screw
Socket-head screw
Socket-head screw
Socket-head screw
Socket-head screw
Socket-head screw
Socket-head screw
Socket-head screw
Socket-head screw
Socket-head screw
Socket-head screw
Socket-head screw
Socket-head screw
Socket-head screw
Socket-head screw
Grub screw
Nut
Nut
Driver

Nut

For component

Tightening torque

(Nm)

Starter cover

1.8

Handle moulding / handle

1.8

Retainer, stop rods

1.8

Handle / handle mount

8.0

Tank housing left / right

7.5

Filter base / carburetor

3.5

Cover, clamp / cast arm

4.5

Handle / tank housing

8.0

Air guide cover / crankcase

4.5

Muffler / crankcase

10.0

Muffler / cylinder

10.0

Cast arm / crankcase

10.0

Filter base / crankcase

6.0

Filter housing / filter base

4.0

Shroud / tank housing

6.0

Crankcase left / right

10.0

Fan cover / tank housing

6.0

Starter cover / cast arm

6.0

Cylinder / crankcase

10.0

Ignition module / crankcase

8.0

Support / handle / tank housing

8.0

AV element, cast arm / handle

6.0

AV element, tank housing / cast arm

6.0

AV element, tank housing / crankcase, left

6.0

Tank housing / carburetor

4.0

Flywheel

30.0

Starter wheel

23.0

Clutch

40.0

Spark plug

27.5

V-belt pulley / bearing

37.5

Decompression valve

14.0

Remark

1)

2)

When screwing the DG screws into an existing screw thread:

-

Insert the DG screw in the hole and turn counterclockwise until it gently drops into the hole in axial direction.

-

Turn the screw clockwise and tighten with the specified torque.

This procedure guarantees that the screw engages in the existing screw thread without cutting a new thread and thus
prevents the strength of the screw connection being weakened.

1) Secure screw with adhesive 0786 111 1109 (Loctite 270).
2) A washer must be fitted under the head of the screw.

Note: 

Screws secured with adhesive must be heated with a hot-air fan (drier) in order to release them.

Great care must be exercised with plastic parts!

Содержание TS 400 Cutquick

Страница 1: ...pecial tools and service accessories 50 11 1 Special tools 50 11 2 Service accessories 52 TABLE OF CONTENTS 1 Introduction 2 2 Specifications 3 2 1 Engine 3 2 2 Fuel system 3 2 3 Ignition system 4 2 4...

Страница 2: ...ement parts list until a new edition is published The special tools mentioned in the text are listed in the last chapter of this Manual The tools can also be identified in the manual of STIHL tools on...

Страница 3: ...screw H Low speed adjusting screw L Leakage testing of the carburetor with excess pressure Fuel tank capacity Octane rating Fuel mix Mixing ratio Air filter 64 1 cm 3 49 mm 34 mm 9 5 1 3 2 kW 4 4 HP...

Страница 4: ...achment for wet cutting V belt guard kit Bearing with guard D 300 Set of gaskets Set of carburetor parts Sealing panel Transistor controlled non contacting magneto ignition with integrated controller...

Страница 5: ...8 Handle moulding handle 1 8 Retainer stop rods 1 8 Handle handle mount 8 0 Tank housing left right 7 5 Filter base carburetor 3 5 Cover clamp cast arm 4 5 Handle tank housing 8 0 Air guide cover cran...

Страница 6: ...ew 1 in the thrust washer 2 Remove thrust washer Remove woodruff key 1 from groove in shaft Remove washer 2 from shaft Unscrew bearing screws 1 Remove guard 2 Remove axial clamping ring from shaft Rem...

Страница 7: ...Remove flange Remove washer and rubber ring Press both deep groove ball bearings and the ring out of the bearing with drift pin 1 The parts are reassembled in reverse order Draw bearing out of rubber...

Страница 8: ...ut with 37 5 Nm Position the deep groove ball bearing and press in with shaft until it rests against circlip Draw shaft out of deep groove ball bearings Insert second circlip in groove of bearing Impo...

Страница 9: ...fastening screws Turn hexagon of clamp clockwise The clamp comes within range of the spring force after approx 1 8 of a turn It must be then be turned to the limit approx 1 8 of a turn Note The wrenc...

Страница 10: ...ng faces not level parts are not original STIHL parts Spindle shaft damaged Tangible radial play in the bearing seat spindle bearing defective Possible causes Fastening screw loose during operation wr...

Страница 11: ...elt from V belt pulley The parts are reassembled in reverse order Note The screws of the starter cover must be tightened with a torque of 6 Nm Remove circlip Note The ball bearing must be pressed in a...

Страница 12: ...letely detensioned Remove the clamping lever from the housing slot The parts are installed in reverse order Insert both parts together Tighten the fastening nuts with a torque of 4 5 Nm Remove the cla...

Страница 13: ...Troubleshootings standard repairs for troubleshooting procedures Remove V belt see chapter 3 4 Unscrew clutch and attachment from the crankshaft Important The clutch has a left hand thread Remove the...

Страница 14: ...ht with the aid of the carburetor crankcase tester and the vacuum pump 5 2 1 Preparatory steps Draw out the spark arresting screen Clean the spark arresting screen fit new screen if necessary Remove s...

Страница 15: ...no leaks in the crank case if this pressure is maintained for at least 20 seconds Install test flange 1 instead of the carburetor Important The pin must be inserted in the impulse hose 2 correctly whe...

Страница 16: ...negative pressure in crankcase however the rotary shaft seals must be replaced even if the vacuum test did not reveal any leaks Reopen venting screw and remove hose after testing Remove test flange a...

Страница 17: ...out rotary shaft seal Important The crankshaft stub must not be damaged Clean the sealing face with a conventional solvent based degreasing agent without CFCs and halogenated hydrocarbons as describe...

Страница 18: ...rigger slightly and draw throttle rod out of trigger Remove spark plug terminal 1 from spark plug Remove ignition lead and stop switch lead from mount 2 Set choke lever to upward position Slide the ro...

Страница 19: ...e air guide cover The parts are reassembled in reverse order Check that spout for decompres sion valve is located correctly on the shroud Set the slide control to I before assembling the shroud Unscre...

Страница 20: ...ton pin 1 out of the piston with assembly pin 2 Note If the piston pin is stuck it can be released by lightly knocking against the assembly pin with a hammer The pin must be steadied in order not to t...

Страница 21: ...t difficulty when the piston is warm Line up the piston rings the fixing pin must be engaged in the annular groove by the bevelled radii of the ring joint when compressed Slide the cylinder over the p...

Страница 22: ...lopes at the ends facing towards the piston head Install piston see chapter 5 6 2 Screw in the cylinder base screws and alternately tighten them cross wise with a torque of 10 0 Nm Remove piston see c...

Страница 23: ...until they rest against the drilled plate Unscrew the screws from the cast arm Unscrew the screws in the two halves of the housing Note Assembly devices without the holes marked 13 can be modified as...

Страница 24: ...sing half Drive the deep groove ball bearing out with drift pin 1 Check the crankcase halves for cracks and replace if necessary Turn the spindle of the assembly tool counterclockwise until the cranks...

Страница 25: ...driven into the housing half if necessary If the clutch side housing half can not be heated the deep groove ball bearing must be driven in as far as possible with drift pin 1 Screw the threaded sleeve...

Страница 26: ...ning it counter clockwise too the crankshaft must be steadied at the same time Screw M5x72 screws from the set of assembly tools ZS into two holes of the crankcase connection to prevent the housing fr...

Страница 27: ...ew the M5x72 screws fitted to prevent twisting Slide the rotary shaft seal over the assembly sleeve with the open side facing the crankcase Drive in with press sleeve 1 Remove the assembly sleeve afte...

Страница 28: ...sion spring from the ignition lead Grasp ignition lead with pliers and draw it out of the spark plug terminal Draw spark plug terminal off ignition lead Remove cover from ignition lead Remove shroud s...

Страница 29: ...d of the ignition lead which is to be turned into the ignition module Note Before turning in the ignition lead the high voltage output must be filled with STIHL multi purpose grease see 11 2 Caution G...

Страница 30: ...g should therefore be limited solely to spark testing The complete ignition module must be replaced if the ignition spark fails although the leads and stop switch are intact Ignition in the transistor...

Страница 31: ...switch lead out of wire harness 2 and mount 3 Disconnect spark plug terminal from spark plug Draw ignition lead out of retainers Remove stop switch lead from slot 1 and retainers 2 If necessary press...

Страница 32: ...Unscrew the other two screws too Removing the flywheel Press the cap in at the bottom slide it upwards and remove it Press catch 1 down and draw contact sleeve 2 of stop switch lead out of the mount...

Страница 33: ...here must not be any cracks or other signs of damage in the flywheel 1 and magnetic poles 2 otherwise the flywheel must be replaced Turn flywheel so that the magnetic poles are opposite the ignition m...

Страница 34: ...d the starter no longer functions correctly In this case it is sufficient to apply a few drops of petroleum to the rewind spring Carefully pull the starter rope several times and let it rewind smoothl...

Страница 35: ...on starter wheel Hold a short length of starter rope near the rope rotor and turn the rope rotor six times counterclockwise with it Note The rewind spring is correctly tensioned when the starter handl...

Страница 36: ...ers out of rubber buffers Prise rubber buffers out of crankcase Press rubber buffers into cast arm until outer groove 1 engages chamfer 2 Tighten screws with a torque of 6 0 Nm Unscrew screws from rub...

Страница 37: ...ve throttle trigger interlock from bearing Note The leaf spring 1 must be located in front of the slide control and the stop rod 2 below it Set the slide control to I Prise throttle rod 1 out of throt...

Страница 38: ...tab 2 Remove torsion spring from rod The rod is installed in reverse order Unscrew the screws 1 in support 2 Remove support and handle 3 Remove shroud see 5 5 Unscrew the screw 1 on retainer 2 Remove...

Страница 39: ...Handle mount Unscrew fastener for filter cover Remove filter cover Remove handle mount Unscrew the screw 1 in the rubber buffer Unscrew the screws 2 in the handle mount Press rubber buffer in until o...

Страница 40: ...e parts are reassembled in reverse order Draw main filter out of filter housing Note The main filter must be replaced if soiled The auxiliary filter must be replaced at the same time Remove prefilter...

Страница 41: ...rubber bulb 6 and pump air into the carburetor until an excess pressure of approx 0 8 bar is indicated on the pressure gauge There are no leaks in the carburetor if this pressure is maintained If it d...

Страница 42: ...n hose 1 Compress and remove leaf spring 2 Draw choke lever off choke shaft The parts are reassembled in reverse order Unscrew nuts Remove air filter housing Draw carburetor off stud bolts Note Refer...

Страница 43: ...g screws clockwise as far as possible They must then be adjusted as follows H High speed adjusting screw 1 1 turn open L Low speed adjusting screw 2 1 turn open Note If a tachometer is not available t...

Страница 44: ...r 1 and valve Note The filter prevents dirt from entering the valve and compensator reservoir The cap 2 protects the filter against damage and contamination Remove shroud see 5 5 Prise out and remove...

Страница 45: ...ivers sufficient fuel Important The fuel tank and pick up body must always be inspected first if any malfunctions develop in the fuel supply The fuel tank must be cleaned if necessary Remove tank vent...

Страница 46: ...terminal 1 from spark plug Remove ignition lead and stop switch lead from holder 2 Draw impulse hose off connector Note Installation is facilitated by coating the hose flange with a little oil The st...

Страница 47: ...er see 10 7 Remove sleeve from manifold Unscrew the screws in the left half of the housing Press flange of manifold out of the opening in the tank housing Remove manifold from intake port Position man...

Страница 48: ...rubber buffers Press contact spring holder out of slot Remove holder Unscrew the screws 1 of handle 2 Unscrew the screws 3 on support 4 Remove support Remove that half of the housing Force out impulse...

Страница 49: ...til the sloping edge 3 engages in slot 4 Use a new gasket Tighten the screws in the two housing halves with a torque of 7 5 Nm Unscrew filler cap Disconnect chain holding cap The parts are reassembled...

Страница 50: ...850 6000 0000 890 9100 5910 893 8800 5910 850 3100 4110 893 7800 Use Rem Locking the crankshaft Sealing the exhaust during leakage tests Mounting the piston Tensioning the piston rings Leakage testing...

Страница 51: ...crew connections 0 5 to 18 Nm 1 2 Screw connections 6 to 80 Nm 1 2 For all IS screws 3 Attaching plugs to electrical leads Extracting the flywheel Nut for flywheel Clutch Tightening the IS screws Driv...

Страница 52: ...onventional solvent based degreasing agent without CFCs and halogenated hydrocarbons 3 HTR ignition lead 10 m 4 STIHL multipurpose grease Part No 0781 120 1111 0000 930 2251 0781 120 1109 Use Rotary s...

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